Broken Lionel ZW roller spring/arm.. help!

[ChiefEagles]

Train Tender or Dr. Tinker should have what you need. Ditto on the 'three hands'. A buddy of mine and I did this exact repair on a 'condemmed' ZW that I got as a freebie 'bout three years ago. We replaced a copper arm, worn rollers, broken handles, chopped line cord, broken terminal screw, bad circuit breaker, missing screws and light lenses, burnt pilot light. For about $35 in parts, I got a perfectly running ZW now, and use it a lot.

If I remember, there's a light tension spring and a mounting pin. One has to push the old copper arm into the spring a little to get the tension off the pin that holds it onto the control arm shaft. Have a helper pull the pin out with needle nose pliers, and the arm should come out. Reverse procedure for installation. I believe the outside control A or D arms were easier than the inner B or C arms. Shouldn't have to do more than just take the lid off to remove your broken arm.

Rollers aren't hard. Just use a pair of slip joint pliers and crush up the old rollers, and cut out the old roller rivet with a pair of diag cutters. Install the new rollers and rivet, and very lightly peen the open end of the new rivet with a nail set and small ball peen hammer. Best done when arms are out of the unit.

CJ Meyers
South Jersey

 

IF you follow the above, use a piece of card stock like a parts card with the string attached.  This is a great spacer to insure the roller had room to turn.  You do not want the roller where is can not roll.  Cut a v slot in the card.  Insert the card in between the roller and the copper arm. Then ping as he said.  Do not solder.    

[cjmeyers]

Train Tender or Dr. Tinker should have what you need. Ditto on the 'three hands'. A buddy of mine and I did this exact repair on a 'condemmed' ZW that I got as a freebie 'bout three years ago. We replaced a copper arm, worn rollers, broken handles, chopped line cord, broken terminal screw, bad circuit breaker, missing screws and light lenses, burnt pilot light. For about $35 in parts, I got a perfectly running ZW now, and use it a lot.

If I remember, there's a light tension spring and a mounting pin. One has to push the old copper arm into the spring a little to get the tension off the pin that holds it onto the control arm shaft. Have a helper pull the pin out with needle nose pliers, and the arm should come out. Reverse procedure for installation. I believe the outside control A or D arms were easier than the inner B or C arms. Shouldn't have to do more than just take the lid off to remove your broken arm.

Rollers aren't hard. Just use a pair of slip joint pliers and crush up the old rollers, and cut out the old roller rivet with a pair of diag cutters. Install the new rollers and rivet, and very lightly peen the open end of the new rivet with a nail set and small ball peen hammer. Best done when arms are out of the unit.

CJ Meyers
South Jersey

 

[ChiefEagles]

Can be a "three handed" job but can be done.  There is an OGR backshop video and some old articles on rebuilding Post War ZW's [I love them].  Don't think CTT ever ran any on rebuild them.  OGR run 197 starts a series on rebuilding ZW's.  I think you can buy downloads of those issues that gave the instructions.

[rtraincollector]

try jeff at the train tender www.ttender.com or email him at [e-mail] hes my main source for any parts hes quick to ship also. and very helpfull for what you need.

[Anonymous]

I've just gotten back into model trains (O scale...up from HO when i was a kid!) and have decided to go the vintage lionel route.

 I was given a old used ZW transformer and when i opened it up i found two of the copper rollersprings/arms were mangled beyond hope. Where can i get replacements for these? Other than these two parts (and the chewed up carbon rollers on them) the ZW is in good shape.

 Any help would be appreciated!

 Thanks,

 Jason